Appliance with bilayer base

ABSTRACT

A bilayer base for attaching appliances selected from the group consisting of a component of a dental appliance, an orthodontic appliance, or an orthopedic appliance to a bony part of the human body wherein the appliance part to be attached to the bony part of the body may be made of metal, ceramic, or plastic. The base permits the appliance to be ready for mounting and includes a cured layer of polymer resin mounted on the appliance and an uncured layer of substantially the same polymer resin over the cured layer which when cured becomes integral with the cured layer in attaching the appliance to a bony part of the body.

This invention relates in general to a ready appliance for immediateattachment to a bony part of the human anatomy, and more particularly toan adhesive base on the appliance having a cured layer of plasticmaterial attached to the appliance and an uncured layer of substantiallythe same material to be cured at the time of mounting the appliance on abony part of the human anatomy.

BACKGROUND OF THE INVENTION

Heretofore, it has been known to provide prepasted orthodonticappliances (appliances having uncured adhesive on the mounting side) toorthodontists for immediate mounting on teeth, without requiring theorthodontist to apply adhesive, like the appliances disclosed in U.S.Pat. Nos. 4,204,325 and 4,978,007. Such prepasted orthodontic appliancesinclude a body provided with an uncured layer of chemically curable orlight-curable adhesive on the mounting side which when cured attachesand secures the appliance to a tooth. It is well known that this type ofan orthodontic appliance generally includes a metal mesh base to whichthe uncured layer of adhesive is applied prior to being sold to anorthodontist. And it is known that such an adhesive may belight-curable, chemically curable, or heat-curable, althoughlight-curable adhesives like disclosed in the U.S. Pat. No. 4,978,007patent are preferred.

An appliance with a cured polymer resin base has also been known for aceramic orthodontic bracket, as disclosed in U.S. Pat. Nos. 5,098,288and 5,263,859, wherein the base facilitates removal of the bracket fromthe tooth without damaging the tooth. Such brackets have been sold by TPOrthodontics, Inc. of LaPorte, Ind., under the trademark Mxi. The basesof these brackets have been transparent and translucent as disclosed incopending applications Ser. No. 10120,052 filed Apr. 10, 2002, and Ser.No. 10/224,770 filed Aug. 21, 2002, which applications are assigned toTP Orthodontics, Inc., like the present application, and areincorporated herein by reference.

SUMMARY OF THE INVENTION

The present invention is in providing a bilayer base for orthodonticappliances or orthopedic prosthetics to be ready for immediate mountingon the bony part of the human anatomy. The bilayer base includes a layerof cured plastic material of a suitable polymer resin and which ispermanently mounted on the appliance. A further layer of uncured polymerresin is applied to the cured layer and the appliance is then suitablypackaged and shipped to an orthodontic or orthopedic customer, whomounts the appliance onto a bony part of the human anatomy, cures theuncured layer of polymer resin, thereby defining an integral base thatis cured onto the bony part of the human anatomy.

The polymer resin of the cured layer, as well as the uncured layer, isof substantially the same type and from the same family of resins andmay be cured by light energy, chemical energy, or heat energy.Preferably the polymer resin is of a type that is light-curable, andwith respect to this version, the cured layer serves to wick or transmitthe curing light energy to the entire uncured layer, thereby enhancingthe curing step to produce a strong bond. The cured layer of resin is ofany suitable polymer resin such as an acrylic, an epoxy or anacrylic-based epoxy. For example, an orthodontic appliance, such as abracket, that may be of metal, ceramic, or plastic would first beprovided with a layer of the polymer resin which would be cured todefine the first layer of a bilayer base. Secondly, an uncured layer ofsubstantially the same polymer resin would be applied to the cured layerand the appliance with this bilayer base would be suitably packaged andship ed to an orthodontic customer, who would mount the bracket on atooth, after suitably preparing the tooth, and thereafter cure orpolymerize the uncured layer of resin to effect attachment of thebracket to a tooth.

Similarly, the bilayer base can be used for orthopedic prosthesisassemblies such as where a hip, knee or other joint replacement issatisfied with the implantation of an orthopedic prosthesis. One part ofthe prosthesis would normally include a stem that would be inserted intoa canal of a bone. According to the present invention, the stem wouldhave the bilayer base of a suitable polymer resin and at the time ofmounting on a bone the uncured layer of adhesive would be activated bylight, chemical, or heat energy to attach the part to a bone of thehuman anatomy. As above explained with respect to the bilayer base on anorthodontic appliance having a light-cure resin, the cured layer servesas a light bar or conduit to allow the light energy to blanket theuncured layer.

Accordingly, the ready-made bilayer base of the present invention couldbe used in the dental or orthopedic field for attaching appliances tothe bony structure of the body.

It is therefore an object of the present invention to provide a new andimproved bilayer base for appliances to be mounted on bony parts of thebody including teeth and bones.

Another object of the present invention is to provide for an appliancewith a bilayer base to be mounted on a bony part of the body whereinbecause of the materials of the base a greatly enhanced bondingstructure will be established between the appliance and the bony part ofthe body.

A further object of the present invention is to provide a readyappliance for the convenience of the user such as an orthodontic brackethaving a bilayer base with a cured layer and an uncured layer of polymerresin that not only enhances the bonding strength of the base to a bonypart of the body but also facilitates the removal of the base at a timewhen the bracket is to be removed.

A still further object of the present invention is to provide anorthodontic appliance, in the form of a bracket, tube or button with aready bilayer base that facilitates the handling of the appliance at atime when used by an orthodontist to mount on a tooth wherein thebilayer base includes a cured layer of polymer resin on the appliancebody and an uncured layer of polymer resin over the cured layer and fromthe same family of resins as the cured layer, wherein the uncured layerwould be cured at the time of mounting the appliance on a tooth and forman integral base for the appliance.

A further object of the present invention is to provide a bilayer baseincluding a transparent or translucent cured layer and an uncured layerof transparent or translucent light-curable resin for an orthodontic ororthopedic appliance, wherein the cured layer functions to wick ortransmit the curing light energy over the entire layer of uncured resinto produce curing of the entire uncured layer and a better bond betweenthe appliance and the surfaces on which the appliance is to be attached.

Other objects, features and advantages of the invention will be apparentfrom the following detailed disclosure, taken in conjunction with theaccompanying sheets of drawings, wherein like reference numerals referto like parts.

DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an orthodontic bracket mounted on atooth with the bilayer base of the present invention;

FIG. 2 is a vertical cross-sectional view taken through an orthodonticbracket like that in FIG. 1 wherein the first layer of the bilayer basehas been applied to the bracket body and cured;

FIG. 3 is a view similar to FIG. 2 but also showing the layer of uncuredpolymer resin in place over the cured layer to define a bracket readyfor mounting on a tooth;

FIG. 4 is a vertical sectional view taken substantially along line 4—4of FIG. 1 and illustrating the second layer of the base cured and thatit becomes integral with the initially cured layer to provide thecomplete base for the appliance according to the present invention;

FIG. 5 is a cross-sectional view of an orthopedic prosthesis having theinitial cured layer of the bilayer base according tot he presentinvention;

FIG. 6 is a view similar to FIG. 5 and further showing the layer ofuncured polymer resin over the cured layer of polymer resin and therebydepicting the appliance as it would be delivered to a user desiring toinstall the appliance on the bone of a person; and

FIG. 7 is a sectional view taken through the appliance of FIGS. 5 and 6and a bone to which the appliance is attached and illustrating the curedand uncured layer as being integral and attached to the bone of aperson.

DESCRIPTION OF THE INVENTION

Referring now to the drawings, and particularly to FIGS. 1 to 4, anorthodontic bracket 10 is shown in mounted position on a tooth 11 inFIGS. 1 and 4 to illustrate the invention. It will be appreciated thatthe bracket 10 includes a bracket body 14 and a base 16.

While the bracket body 14 illustrates a bracket of a type that is soldby TP Orthodontics, Inc. of LaPorte, Ind., it will be appreciated withrespect to the invention the bracket body may be of any suitable typeand of any suitable material. Moreover, the invention, being directedprimarily to the base, can be used on any appliance that would bemounted on a tooth, including a bracket, a molar tube, or a lingualbutton, an implantable stem for a tooth implant, or other appliancedesired to be bonded to a tooth or the jaw for purposes of dentally ororthodontically treating a patient. Thus, the appliance body 14 may beof any type that would be useful in treating the dentition of a patient,orthodontically or otherwise, where it would be desired to adhesivelybond an appliance in a desired place. Moreover, as will be discussedfurther below, the base of the invention can be used for orthopedicappliances to mount a part of a prosthesis on a bone of a person.

The body of the appliance, and in this case the bracket 14, may be madeof any suitable material for an orthodontic appliance, such as metallike stainless steel, ceramic, or plastic. Similarly, if the appliancebody is a buccal tube, it can be made of any of these materials. As seenparticularly in FIGS. 2, 3 and 4, the bracket body 14 includes anarchwire receiving side 18 and a base receiving side 20. The base 16 ismounted onto the base receiving side 20.

The bracket is made by suitably preparing the surface of the bracketbody and then molding or otherwise applying a first layer 22 of apolymer resin to the bracket and then curing that layer. Preferably, thelayer includes edges that overlap the edges of the bracket body asillustrated in order to provide the best possible bonding or connectionbetween the layer 22 and the bracket body and also enhance thetransmission of light during the curing of the second layer. This stepof the manufacture is illustrated in FIG. 2 where only the cured layer22 is shown on the mounting side of the bracket.

Next, a second layer 24 of a polymer resin is suitably applied over thefirst layer 22. This layer is maintained in an uncured state, andtherefore the appliance is provided to the orthodontic customer so thatthe orthodontist, after preparing the tooth on which the bracket is tobe mounted, can merely apply the bracket with the bilayer base onto thetooth and then cure the second layer 24 accomplishing the mounting orattachment of the bracket to the tooth. Once the second layer is cured,it will merge and be essentially integral with the first layer as thebase of the bracket, as shown in FIG. 4, and thereby provide thecomplete bonding connection between the bracket and the surface of thetooth 11.

The polymer resin of the first layer 20 may be acrylic, epoxy oracrylic-based epoxy resin, or any other suitable resin. Further, theresin may be of a type that is light-curable, chemically curable, orheat-curable. Preferably, the resin is of a type that is light-curable.Moreover, the second layer 24 is of a polymer resin in the same polymerresin family as the polymer resin of the first layer 22. Preferably, thepolymer resins are substantially identical to one another, and anacrylic-based epoxy that is light-curable. As long as the resins of eachlayer are from the same family, which enhances the bonding between thelayers, the curing/polymerization process of each need not be the same.For example, the cured layer may be heat cured, while the uncured layermay be light-curable.

It will be appreciated that the bracket with the bilayer base having acured layer of polymer resin and an uncured layer of polymer resin willbe shipped and transported to a customer in such a way as to protect theintegrity of the uncured layer and also prevent it from curing duringthe time it is in transport. One method of transporting the appliancewith the bilayer base is to flush it with nitrogen to preserve theuncured state of the adhesive resin and then hermetically seal it in apackage to prevent light from activating the curing cycle of the uncuredadhesive. Where the base is of a light-curable resin, the transparent ortranslucent cured layer further functions as a light conduit for thecuring light energy to allow the energy to fully activate the uncuredlayer of resin and fully cure the layer to fully bond the appliance tothe mounting surface. Thus, the light energy wicks or moves easily alongthe cured layer. One of the layers may be transparent, while the otherlayer is translucent. Preferably, the cured layer is transparent tooptimize the transmission of the curing light energy.

Thus, the bracket of the invention, having a bilayer base, is ready forthe orthodontist to mount on a tooth and thereafter to direct a curinglight at the uncured layer of the polymer resin to cure the layer andfirmly attach the bracket to a tooth.

The bilayer base of the invention is illustrated as being applicable toan orthopedic prosthesis in FIGS. 5 to 7, wherein FIG. 6 shows anelongated stem 30 over which the bilayer base 32 has been formed todefine a prosthetic part ready to be used by the orthopedic customer forattachment to a bone following light-curing of the uncured layer of thebase. The base 32 includes a cured layer 34 of a polymer resin overwhich an uncured layer 36 of substantially the same, if not the same,polymer resin is provided to complete the base.

FIG. 5 shows the orthopedic stem 30 with only the cured layer 34 appliedto the stem in the manufacture of the bilayer base. Thereafter, theuncured layer 36 is added before shipping the stem to an orthopediccustomer, as shown in FIG. 6.

It will be appreciated that the orthopedic prosthesis stem 30 could bemade of any suitable material, such as metal, ceramic, or plastic, andbe formed for use in any articulated part of the human anatomy. Theparticular appliance stem 30 shown is intended to be used for a hipreplacement procedure to replace a part of a diseased femur 38. A canal40 is suitably formed, such as by drilling, in the end of the femur andinto which the end of the prosthetic device is inserted.

It will be appreciated that with respect to artificial kneereplacements, as well as hip replacements, cemented and uncementedprostheses may be used. The present invention relates only to the use ofa cemented prosthesis, and as above mentioned, the stem 30 may be madeof any suitable material although it is usually made of metal. Again,the appliance with the bilayer base as shown in FIG. 6, wherein theouter layer 36 is provided in an uncured state before being provided toa customer like the above described orthodontic appliance. Also, like anorthodontic appliance with the base of the invention, the prosthesiswould be flushed with nitrogen and then hermetically sealed in acontainer that would not allow any light transmission to prevent curingof the light-curable polymer resin layer of the bilayer base whenshipping the prosthesis to an orthopedic customer.

It will be appreciated that the polymer materials of the bilayer basemay be of the same type as above identified with respect to theorthodontic appliance. And where the polymer material of the uncuredlayer is light-curable, and the cured layer is transparent ortranslucent, the cured layer further functions to wick or transmit thelight energy of a curing light to the entire uncured layer.

FIG. 7 illustrates the orthopedic part 30 having its bilayer base inplace in a canal of a femur and the uncured layer, wherein the cured anduncured layers of the base integrally join together during the time theuncured layer attaches to the bone of the femur and connects the part tothe femur.

It will be appreciated that the illustrations of an orthodontic bracketand a part of a prosthetic artificial joint are merely illustrative ofthe scope and use of the bilayer base according to the invention as itcould be used in connection with any artificial part that is to besecured to a bone or tooth of the body.

It will be understood that modifications and variations may be effectedwithout departing from the scope of the novel concepts of the presentinvention, but it is understood that this application is to be limitedonly by the scope of the appended claims.

What is claimed is:
 1. The combination of a factory-made orthodonticappliance and a laminated base for shipment to a user for ready mountingof the appliance on a tooth, said base comprising: a first layer ofcured polymer resin, and a second layer of uncured polymer resin ofsubstantially the same family as the first layer defining a tackysurface for ready mounting of the appliance on a tooth.
 2. Thecombination of claim 1, wherein said appliance is a bracket or a tube.3. The combination of claim 1, wherein said appliance is of metal,ceramic, or plastic material.
 4. The combination of claim 1, whereinsaid polymer resin is light, chemical, or heat-curable.
 5. Thecombination of claim 1, wherein said polymer resin is from the group ofacrylic, epoxy, or acrylic-based epoxy resins.
 6. The combination ofclaim 1, wherein said polymer resin is transparent or translucent. 7.The combination of a factory-made appliance and a base thereon forshipment to a user and ready mounting of the appliance on a bone of aperson, said base comprising, a first layer of cured polymer resin, anda second layer of uncured polymer resin of substantially the same familyas the resin of the first layer defining a tacky surface for readymounting of the appliance on a bone of a person that engages the boneand is cured thereafter to be integral with the first layer and attachthe appliance to the bone.
 8. The combination of claim 7, wherein theappliance is an orthopedic appliance of metal, ceramic or plasticmaterial, and the polymer resin is from the group of light, chemical, orheat-curable resins.
 9. A factory-made bilayer base for an appliance forshipment to a user and mountable on bones and/or teeth of the humananatomy, said base comprising: a first layer of a polymer resin in acured state, and a second layer of a polymer resin in an uncured statesuperposed over the first layer defining a tacky surface for readymounting of the appliance on a tooth, said polymer resins of both layersbeing of substantially the same type, whereby application of theappliance to a selected part of the human anatomy and curing of saidsecond layer causes said second layer to be integral with the firstlayer, and firmly mounts the appliance to said selected part.
 10. In afactory-made appliance selected from the group consisting of a componentof a dental appliance, an orthodontic appliance, or an orthopedicappliance for shipment to a user, wherein the appliance includes meansthereon for attaching at least part of the appliance to a bony part ofthe human body, and which component includes a part made of metal,ceramic or plastic and said attaching means is a base secured to thepart, the improvement being in the attaching means which comprises acured layer of polymer resin mounted directly on said part, and anuncured layer of polymer resin over at least a part of the cured layerdefining a tacky surface for ready mounting of the appliance on a bonypart of the human body and which when cured becomes integral with thecured layer and attaches the part to said bony part.
 11. In an applianceaccording to claim 10, wherein the polymer resin of the uncured layer isof the same family of resins as the polymer resin of the cured layer.12. In an appliance according to claim 10, wherein the polymer resin ofsaid layers is of a type that is curable by heat energy, chemicalenergy, or light energy.
 13. In an appliance according to claim 10,wherein the polymer resin of said layer is transparent or translucent.14. In an appliance according to claim 10, wherein the polymer resin ofthe uncured layer is light-curable and the polymer resin of the curedlayer is transparent or translucent, whereby the cured layer functionsto wick or transmit light energy to the entire uncured layer and producecomplete curing of the uncured layer.
 15. The combination of afactory-made orthodontic appliance and a laminated base for shipment toa user for ready mounting of the appliance on a tooth, said baseconsists of: a first layer of cured polymer resin, and a second layer ofuncured polymer resin of substantially the same family as the firstlayer defining a tacky surface for ready mounting of the appliance on atooth.